In situ TiC reinforced Al composite has been synthesized from the reaction between Ti and activated carbon. The size of in situ TiC is in the range from sub-micron to a maximum of 1.7 μm. Degree of reaction between Ti and activated carbon increases with increasing reaction temperature and amount of carbon. At low reaction temperature, the tensile strength of the composite is low as a result of the presence of unreacted activated carbon retained in the material. The retained carbon can be reduced by increasing reaction temperature. It has been observed that at low reaction temperature formation of Al3Ti is a dominant phenomenon while at high reaction temperature Al3Ti is not stable. Along with its disappearance, formation of TiC becomes favorable. (C) 2000 Elsevier Science Ltd. All rights reserved.